U.S. patent number 8,173,924 [Application Number 12/294,332] was granted by the patent office on 2012-05-08 for dual function switch assembly.
This patent grant is currently assigned to Illinois Tool Works Inc.. Invention is credited to Juan J. Barrena, Robert Dam, Richard D. Gjerde, Michael W. Hartley, Richard R. Herzog, Ronald R. Hostert, David R. Nowak, Robert G. Tegel, Theodore James John Veselsky.
United States Patent |
8,173,924 |
Tegel , et al. |
May 8, 2012 |
Dual function switch assembly
Abstract
A dual function switch assembly includes a switch housing part
containing multiple switches at different elevations and a rotor
having cam surfaces aligned with the switches for operating the
switches. A mounting part is connected to the switch housing part
and provides mounting features for attachment in a desired
installation.
Inventors: |
Tegel; Robert G. (Glenview,
IL), Dam; Robert (Glenview, IL), Hartley; Michael W.
(Glenview, IL), Gjerde; Richard D. (Glenview, IL),
Herzog; Richard R. (Glenview, IL), Nowak; David R.
(Glenview, IL), Hostert; Ronald R. (Glenview, IL),
Veselsky; Theodore James John (Glenview, IL), Barrena; Juan
J. (Glenview, IL) |
Assignee: |
Illinois Tool Works Inc.
(Glenview, IL)
|
Family
ID: |
38846443 |
Appl.
No.: |
12/294,332 |
Filed: |
June 25, 2007 |
PCT
Filed: |
June 25, 2007 |
PCT No.: |
PCT/US2007/072005 |
371(c)(1),(2),(4) Date: |
March 20, 2009 |
PCT
Pub. No.: |
WO2008/002863 |
PCT
Pub. Date: |
January 03, 2008 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20090321231 A1 |
Dec 31, 2009 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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60816544 |
Jun 26, 2006 |
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Current U.S.
Class: |
200/569;
200/61.86; 200/6BB; 200/568; 200/564; 200/6B |
Current CPC
Class: |
H01H
1/585 (20130101); H01H 19/62 (20130101); F24C
3/126 (20130101); H01H 3/0206 (20130101); H01H
19/08 (20130101); H01H 19/04 (20130101) |
Current International
Class: |
H01H
19/62 (20060101); H01H 9/06 (20060101) |
Field of
Search: |
;200/11R-11K,6R-6C,16R-16D,61.85,61.86,564-569,336 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
ISR for PCT/US2007/72005 dated Feb. 25, 2008. cited by
other.
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Primary Examiner: Friedhofer; Michael
Attorney, Agent or Firm: Lowe Hauptman Ham & Berner
LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
The present regular United States patent application claims the
benefits of U.S. Provisional Application Ser. No. 60/816,544, filed
on Jun. 26, 2006.
Claims
What is claimed is:
1. A multifunction switch assembly comprising: a switch housing
part having a base; first and second switches disposed in said
switch housing part at different relative elevations with respect
to said base; a switch actuating rotor having first and second
peripheral profiles aligned with said first and second switches,
respectively; and a mounting part overlying said first and second
switches and having an outward feature for attaching said switch
assembly in an installation, said switch mounting part and said
switch housing part adapted for engagement one with the other;
wherein said rotor has a notch extending along an axial direction
of the rotor, and said switch housing part has a post extending
from the base along the axial direction of the rotor and being
received in said notch for inhibiting unintended rotation of said
rotor relative to said switch housing part.
2. The switch assembly of claim 1, said first and second switches
comprising pairs of interchangeable resilient contacts.
3. The switch assembly of claim 2, each said resilient contact
having: an elongated, flat body with opposite ends, and an end
portion extending directly from one of the opposite ends of the
elongated flat body and obliquely towards the other resilient
contact in the same pair of interchangeable resilient contacts.
4. The switch assembly of claim 3, each said contact having an
axially oriented slot with an end opening at the other of the
opposite ends of the elongated flat body for engaging an electrical
conductor.
5. The switch assembly of claim 1, said the post received in the
notch inhibits the unintended rotation of said rotor relative to
said switch housing part both clockwise and counter-clockwise.
6. The switch assembly of claim 1, said switch housing part and
said mounting part having complementary engagement features for
securing one to the other.
7. The switch assembly of claim 6, said engagement features being
non-symmetrical.
8. The switch assembly of claim 7, said engagement features
including a loop on one of said switch housing part and said
mounting part and a protrusion on the other of said switch housing
part and said mounting part, said protrusion being received in said
loop.
9. A switch assembly, comprising: a first unitary molded body
defining a first switch part containing contacts therein for first
and second switches and a rotor for actuating said switches, said
rotor having first and second annular profile portions aligned with
said first and second switches respectively, and; a second unitary
molded body defining a second switch part overlying said first
switch part and including connecting features for mounting said
switch assembly in an installation; wherein each of said first and
second switches has a pair of inter-changeable switch contacts;
each of said switch contacts has: an elongated body with opposite
ends, and an end portion extending directly from one of the
opposite ends of the elongated body and obliquely towards the other
switch contact in the same pair of interchangeable switch contacts,
for providing wiping contact against the other switch contact; each
of said switch contacts has an axially oriented and end opening
slot at the other of the opposite ends of the elongated body for
electrically engaging an electrical conductor; and each said
elongated body has dimples along a length thereof for improving
rigidity.
10. The switch assembly of claim 9, said first and second switch
parts defining an axially aligned opening therethrough.
11. The switch assembly of claim 9, at least one of said first and
second switch parts having strain relief ridges along a path for a
conductor extending therethrough.
12. The switch assembly of claim 9, said first and second switch
parts and said rotor defining an open passage through said switch
assembly.
13. The switch assembly of claim 9, said first switch part having a
base defining an aperture and a rim on an outer surface of said
base surrounding said aperture.
14. A wire harness, comprising: first, second, third and fourth
conductors; a switch assembly having a first switch therein
electrically connected to said first and second conductors, and a
second switch therein electrically connected to said third and
fourth conductors; and a rotor disposed between said first and
second switches and including first and second circumferential
profiles aligned with said first and second switches, respectively;
wherein said third and fourth conductors are stacked on said first
and second conductors, respectively: said conductors extend from a
first side of the rotor to a second, opposite side of the rotor;
and the first switch and the second switch are arranged on said
first side and second side of the rotor, respectively.
15. The wire harness of claim 14, each of said first and second
switches having a pair of switch contacts, and all of said switch
contacts of said first and second switches being interchangeable
one with another.
16. The wire harness of claim 15, each said contact having an
elongated body, an inclined end at one end of said body and an
insulation displacing contact slot at an opposite end of said body;
wherein the inclined end extends directly from said one end of the
elongated body and obliquely towards the other switch contact in
the same pair of switch contacts; and wherein an entirety of each
said contact, except for said inclined end, is located in a single
plane.
17. The wire harness of claim 16, said insulation displacing
contact slot being axially oriented in said body and have a
laterally oriented opening at said opposite end.
18. The wire harness of claim 14, including two said switch
assemblies each having two switches therein.
19. The wire harness of claim 14, said switch assembly having a
switch housing part containing said first and second switches and
said rotor; and a mounting part connected to said switch housing
part and including a connecting fixture for attaching said switch
assembly within an appliance.
20. The wire harness of claim 14, said third and fourth conductors
being contactable with said first and second conductors,
respectively, between said switches.
Description
FIELD OF THE INVENTION
The present invention relates generally to electrical switch
assemblies that are actuated by rotatable members, and, more
particularly the invention pertains to switches used in wiring
harnesses such as on appliances, including ignition systems for gas
fired appliances, outdoor cooking equipment and the like.
BACKGROUND OF THE INVENTION
Electrical switches having rotatable actuators are used in a
variety of applications. For example, it is known to use such
switches in gas fueled cooking appliances. An electrical switch
assembly is coupled to the rotatable valve stem of the gas valve,
to control burner ignition circuitry. When the gas valve stem is
rotated to place the valve in the open position and commence gas
flow, the burner ignition electrical circuitry is energized to
ignite the gas stream at the burner. In this way, stand-by pilot
lights are not required, and gas ignition occurs simultaneously
with opening the gas valve and commencing the flow of gas. Fuel is
not wasted keeping a pilot light burning. Considerable fuel savings
can be experienced, particularly in appliances that are used
infrequently, with prolonged periods of nonuse. Pilot-less ignition
systems conserve fuel and thereby improve appliance efficiency.
U.S. Pat. No. 5,687,836 entitled "ELECTRICAL SWITCH ASSEMBLY
ACTUATABLE BY A ROTATABLE MEMBER", issued Nov. 18, 1997, describes
one such electrical switch assembly having utility for gas
appliances. While providing many advantages, the switch assembly
disclosed therein can be used only for a single circuit, and each
switch function in each circuit requires a separate switch.
To improve appliance safety and enhance customer convenience, it is
sometimes desirable to include multiple switching functions upon
actuation or rotation of a single actuator. A variety of indicator
lights to indicate status may be actuated with the primary
function, or may be oppositely actuated. For example, it may be
desirable to illuminate a "burner on" indicator together with
actuation of the ignition circuitry when a gas valve is opened. An
electric circuit to indicate ignition failure can be energized upon
opening the gas valve, to be illuminated if ignition does not occur
within a specific period of time. It may be desirable for various
other safety and/or convenience features that are electrically
operated to be actuated or de-actuated upon opening the gas
valve.
As more and more individual switches for additional functions are
combined with a single actuator, the actuator becomes unduly long
and complex. Individual switches can be electrically connected, one
to another, with only one controlled by the actuator, and others
electrically controlled therefrom. However the wiring harness
becomes unduly large and complex, and requires significant space
for installation. In appliances, it is desirable to minimize space
requirements for controls and the like, to maximize area available
for appliance functions, for example oven interior space, while
minimizing overall appliance size.
U.S. Pat. No. 7,148,440 entitled "STACKABLE SWITCH" issued Dec. 12,
2006, describes a multi-function switch of one type in which
multiple switch functions can be stacked one upon another using an
intermediate housing member having surface topographies suitable
for use in the switches on opposite sides thereof. While the
stackable switch disclosed therein provides multi-switching
functions in a more compact arrangement than utilizing separate
individual switches, in some applications still lower profiles are
desirable. For example, to maintain adequate air flow around gas
valves associated with the switches, still lower profiles are
desirable to minimize the housing and structural dimensions
required to contain the gas valves, gas supply systems and wire
harnesses.
SUMMARY OF THE INVENTION
The present invention provides a dual function switch assembly
having first and second switches contained in a single housing, and
a single rotor having peripheral profiles for operating each switch
upon rotation of the rotor.
In one aspect thereof, the present invention provides a
multifunction switch assembly with a switch housing part having a
base, first and second switches disposed in the switch housing part
at different relative elevations with respect to the base and a
switch actuating rotor having first and second peripheral profiles
aligned with the first and second switches, respectively. A
mounting part overlies the first and second switches and has an
outward feature for attaching the switch assembly in an
installation. The switch mounting part and the switch housing part
are adapted for engagement one with the other.
In another aspect thereof, the present invention provides a switch
assembly with a first switch part containing contacts therein for
first and second switches and a rotor for actuating the switches.
The rotor has first and second circumferential profile portions
aligned with the first and second switches, respectively. A second
switch part overlies the first switch part and includes connecting
features for mounting the switch assembly in an installation.
In a still further aspect thereof, the present invention provides a
wire harness with first, second, third and fourth conductors and a
switch assembly having a first switch therein electrically
connected to the first and second conductors, a second switch
therein electrically connected to the third and fourth conductors;
and a rotor disposed between the first and second switches and
including first and second circumferential profiles aligned with
the first and second switches, respectively. The third and fourth
conductors are stacked on the first and second conductors,
respectively.
An advantage of the present invention, in one form thereof, is
providing a multi-function, multi-switch arrangement that is
compact.
Another advantage of the present invention, in another form
thereof, is providing multiple switches actuated by a single
actuator.
Still another advantage of the present invention, in still another
form thereof, is providing multiple switches that require minimal
space.
Yet another advantage of the present invention, in yet another form
thereof, is providing a multi-function switch assembly in which the
switch components can be pre-assembled in one portion of the
overall assembly that is common to multiple variations of the
assembly and thereafter coupled with another portion of the overall
assembly that is unique to final uses for the assembly.
Other features and advantages of the invention will become apparent
to those skilled in the art upon review of the following detailed
description, claims and drawings in which like numerals are used to
designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a dual function switch assembly in
accordance with the present invention, illustrating the switch
assembly installed in a fragmentary portion of a wire harness;
FIG. 2 is a perspective view of only the switch assembly shown in
FIG. 1, illustrating the side opposite the side shown in FIG.
1;
FIG. 3 is a perspective view of a switch housing part of the switch
assembly shown in FIGS. 1 and 2;
FIG. 4 is a perspective view of the switch housing part shown in
FIG. 3, illustrating the side opposite the side shown in FIG.
3;
FIG. 5 is a perspective view of a switch contact for the switch
assembly shown in the preceding drawings;
FIG. 6 is an elevational view of a pair of switch contacts forming
a switch for the switch assembly in accordance with the present
invention, illustrating the contacts in an open condition;
FIG. 7 is an elevational view of the switch contacts shown in FIG.
6, but illustrating the contacts in a closed condition;
FIG. 8 is a perspective view of a rotor for the switch assembly
shown in the previous drawings;
FIG. 9 is a perspective view of the switch assembly and wire
harness fragmentary portion shown in FIG. 1, with a portion of the
switch assembly removed;
FIG. 10 is a perspective view of a mounting part of the switch
assembly of the present invention, the part being shown in FIG. 1
but removed in FIG. 9;
FIG. 11 is a perspective view of the mounting part shown in FIG.
10, but shown from a different angle;
FIG. 12 is a cross-sectional view of a rotor installed on a valve
stem;
FIG. 13 is a perspective view of another embodiment of a rotor for
a switch assembly in accordance with the present invention;
FIG. 14 is a fragmentary perspective view of a gas appliance having
switch assemblies of the present invention; and
FIG. 15 is a fragmentary perspective view of a mounting part of
another embodiment of the present invention.
Before the embodiments of the invention are explained in detail, it
is to be understood that the invention is not limited in its
application to the details of construction and the arrangements of
the components set forth in the following description or
illustrated in the drawings: The invention is capable of other
embodiments and of being practiced or being carried out in various
ways. Also, it is understood that the phraseology and terminology
used herein are for the purpose of description and should not be
regarded as limiting. The use herein of "including", "comprising"
and variations thereof is meant to encompass the items listed
thereafter and equivalents thereof, as well as additional items and
equivalents thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more specifically to the drawings and to FIG. 14 in
particular, two dual function switch assemblies 20 of the present
invention are shown installed in a gas fired appliance 22. Dual
function switch assemblies 20 are electrically connected in a wire
harness 24 and are operatively associated with gas valves 26. Each
gas valve 26 initiates, controls and terminates gas flow from a gas
manifold 28 to burner assemblies 30, one such burner assembly 30
for one gas valve 26 being illustrated in FIG. 14. Gas valves 26
control flow of gaseous fuel from manifold 28 to burner assemblies
30 via gas supply lines 32. Gas flow at burner assemblies 30 is
ignited by an electronic igniter 34 provided as part of each burner
assembly 30. A signal line 36 to each burner assembly electronic
igniter 34 is operatively and electrically connected to wire
harness 24 through an electronic ignition module (not shown) such
that ignition signals are sent upon the opening of gas valves 26
and the simultaneous operation of switches 20 thereby.
While two switch assemblies 20 are illustrated on wire harness 24
in FIG. 14, those skilled in the art will readily understand that a
single switch assembly 20 may be used where appropriate, and three
or more switch assemblies 20 may be used as part of wire harness 24
when required. The present invention works well with a variety of
actuators such as gas valves 26 in appliances such as kitchen
ranges, outdoor grills and the like. However, it is expected that
switch assemblies 20 of the present invention will have other
suitable uses as well.
Wire harness 24 includes a plurality of electrical conductors 38,
40, 42 and 44 connected to switch assemblies 20 as will be
described in greater detail hereinafter. An electronic ignition
module (not shown) and other suitable control devices are provided
as part of appliance 22 between wire harness 24 and signal line 36.
The design, installation and operation of such devices and gas flow
equipment are well-known to those skilled in the art and will not
be described in further detail herein.
With reference now to FIGS. 1-13, a dual function switch assembly
20 (FIGS. 1 and 2) of the present invention will be described in
greater detail. Dual function switch assembly 20 includes a switch
housing part 60 (FIGS. 3 and 4) mechanically connected to a
mounting part 62 (FIGS. 10 and 11).
Switch housing part 60 contains first and second switches 64, 66,
respectively. Each switch 64, 66 has two similar switch contacts 68
illustrated in FIGS. 5, 6 and 7. Each contact 68 includes an
elongated, substantially flat body 70 having a hooked end 72 at one
end thereof and an insulation displacing contact slot 74 at the
opposite end thereof. A feature of one preferred form of the
present invention is the laterally outwardly opening, axially
oriented insulation displacing contact slot 74 for engaging
conductors inserted from the end thereof. Contact 68 further
includes locating features such as cutouts 76 and/or projections 78
for engaging complementary locating features of switch housing part
60. Further, contact body 70 can have dimples or the like provided
at locations along the length thereof for improving rigidity of
contact 68 while maintaining overall thin and narrow profiles
therefore.
As shown in FIG. 6, a pair of contacts 68 are provided in overlying
arrangement for each switch 64, 66. In the open condition shown in
FIG. 6, contacts 68 are spaced one from the other. In a closed
condition illustrated in FIG. 7, contacts 68 are touching.
Engagement of one contact 68 against the other contact 68 is by the
edge of hooked end 72. As one contact 68 is deflected toward the
other contact 68, a swiping motion is actuated by one hooked end 72
against body 70 of the other contact 68. The swiping motion of the
end edge of hooked end 72 provides a self-cleaning feature for the
area of electrical connection.
A beneficial feature of preferred forms of the present invention is
the use of symmetrical contacts 68 so that each contact 68 in each
switch 64, 66 is the same as the other contacts of switch assembly
20. Therefore, assembly is facilitated in that all contacts are
interchangeable, and the installer need not identify specific
contacts for specific positions. Mechanical, automated assembly is
also facilitated by the use of interchangeable contacts at all
positions.
Switch housing part 60 includes a base 80, opposed side panels 82,
84 and central formations 86, 88, 90 and 92. Each central formation
86, 88, 90 and 92 includes a generally flat wall segment 94 and a
curved barrier segment 96. Wall segments 94 of each formation 86,
88, 90 and 92 confront one or the other of opposed side panels 82,
84 in spaced relation. Contacts 68 in pairs for each switch 64, 66
are restrained between sides 82, 84 respectively, and the wall
segments 94 confronting it.
Along one or both of the opposite sides of base 80 between side
panels 82, 84 a pedestal 98 is provided between adjacent curved
barrier segments 94, one pedestal 98 at each of the sides being
shown in FIG. 3. Curved barrier segments 94 are arranged to define
a space for receiving a rotor 100 therebetween, rotation of which
operates first and second switches 64, 66 as will be described in
greater detail hereinafter.
The pairs of contacts 68 defining first switch 64 and second switch
66 are disposed at different elevations relative to base 80, with
second switch 66 elevated from base 80 by locating features 102.
Thus, as can be seen most clearly in FIGS. 3 and 9, contacts 68 of
first switch 64 are disposed substantially against base 80 while
contacts 68 of second switch 66 are elevated with respect to base
80. Conductors 38, 40, 42 and 44 pass through switch housing part
60 in pairs on opposite sides. On each side, the conductors are
stacked one on top of another. Accordingly, conductors 38 and 40
are provided against base 80 along opposite sides, with each
connected to a different one of the contacts 68 in first switch 64.
Conductors 42 and 44 are provided stacked on top of conductors 38
and 40, respectively, with each electrically connected to a
different one of the contacts 68 in second switch 66. Accordingly,
contacts 68 of second switch 66 are elevated from base 80 by a
dimension approximately equal to the diameters of conductors 38 and
40. The end opening insulation displacing contact slot 74 in each
contact 68 facilitates orderly, compact electrical connection of
conductors 38, 40, 42 and 44 to the contacts, with the conductors
stacked one on another in pairs along the ends of the contacts.
On one side edge of base 80 a single latch loop 104 is provided and
along an opposite side edge of base 80 two latch loops 106, 108 are
provided for mechanical engagement with mounting part 62 to secure
switch housing part 60 and mounting part 62 one to the other, as
will be described in greater detail hereinafter.
Base 80 defines an aperture 110 therein substantially centrally
located between barrier segments 96. On an inner surface of base
80, an annular channel 112 defines a path for rotation of rotor
100. On an outer surface of base 80 an outwardly projecting rim 114
surrounds aperture 110 for redirecting moisture and liquids away
from aperture 110, to inhibit migration of liquids into switch
assembly 20. Within switch assembly 20, wall segments 94 and
barrier segments 96 block and redirect moisture away from contacts
68.
Along opposed sides of base 80, adjacent the ends of contacts 68,
base 80 defines generally L-shaped passages along which conductors
38, 40, 42 and 44 are positioned. Within the L-shaped passages, one
or more ridge 116 is provided to frictionally engage the insulation
of conductors 38, 40, 42 and 44 which extend thereover. Ridges 116
pinch against the conductors and provide strain relief if wire
harness 24 is lifted, moved or stored by grasping one or more of
the conductors 38, 40, 42 or 44. Strain relief ridges provide some
frictional engagement against each of the conductors, to retain the
relative positions of conductors 38, 40, 42 and 44 with respect to
switch assembly 20. Ridges 116 also serve as barriers to the
infiltration of liquids and other contaminants.
Referring now more particularly to FIGS. 10 and 11, mounting part
62 includes a base 120 defining a substantially flat, substantially
unobstructed body having a central aperture 122 therein for
receiving a valve stem therethrough. At the periphery of base 120,
skirts 124, 126, 128 and 130 are provided. Skirt 126 includes an
elongated single protrusion 132 and opposed skirt 130 includes two
protrusions 134, 136. Single protrusion 132 and double protrusions
134, 136 are positioned and sized for engagement with single latch
loop 104 and double latch loops 106, 108, respectively from switch
housing part 60.
Skirts 124, 126, 128 and 130 are spaced one from another to define
openings through which conductors 38, 40, 42 and 44 can pass in
stacked arrangement. Thus, an opening 138 is provided between
skirts 124 and 126. Similar openings 140, 142 and 144 are provided
between, respectively, skirts 126 and 128, 128 and 130, and 130 and
124. Within openings 138, 140, 142 and 144 and along surfaces of
base 120 and skirts 124, 126, 128 and 130, one or more ridge 146 is
provided to frictionally engage the insulation of conductors 38,
40, 42 and 44 extended there over, to pinch against the conductors
and provide strain relief if wire harness 24 or is lifted, moved or
stored by grasping one or more of the conductors 38, 40, 42 or 44.
Strain relief ridges provide some frictional engagement against
each of the conductors to retain the relative positions of
conductors 38, 40, 42 and 44 with respect to switch assembly 20.
Ridges 146 also serve as a barriers to the infiltration of liquids
and other contaminants.
Base 120 further defines one or more locating feature 148, 150 for
positioning mounting part 62 relative to switch housing part 60
and/or for positioning conductors 38, 40, 42 and 44 relative to
conductor openings 138, 140, 142 and 144, and/or for securing
contacts 68 in position within an assembled switch assembly 20.
On an outer surface of mounting part 62, one or more pedestal or
connecting fixture 152, 154, 156 is provided for engagement with
gas valve 26, manifold 28 or other frame and housing components in
which dual function switch assembly 20 is located. An advantageous
feature of the present invention is that mounting part 62 contains
none of the components or elements necessary for operation of
switches 64, 66, all of which can be preinstalled in switch housing
part 60 instead. Accordingly, mounting part 62 can be readily
designed and manufactured for mating with particular components on
which switch assembly 20 will be installed, while the more complex
structure of switch housing part 60 remains standard for multiple
installations.
Base 120, skirts 124, 126, 128 and 130 can be modified as necessary
for ease and convenience in molding and assembly. For example, FIG.
15 illustrates a mounting part 162 defining a leg 164 having a hook
or outcropping 166 and an end thereof. A base 168 of mounting part
162 defines a hole 170 through which a retractable mold pin (not
shown) can be inserted for shaping leg 164 and hooked end 166.
Other slots, apertures, openings or the like can be provided as
necessary and/or convenient for designing and using a mold to form
the necessary parts and components of mounting part 62, for
adaptation to the particular gas valve and/or frame in which it is
installed.
Rotor 100 is the actuator for first and second switches 64, 66 to
operate the switches between closed and opened conditions depending
on the rotational position of rotor 100 with respect to each switch
64, 66. Rotor 100 is a generally cylindrically shaped body having
first and second circumferential outer cam surfaces 180, 182,
respectively. An end body 184 has a non-circular opening 186
therethrough for receiving a noncircular portion of a valve stem
188 from gas valve 26. An end edge 190 of rotor 100 is configured
to ride within channel 112. First cam surface 180 is aligned with
first switch 64, and second cam surface 182 is aligned with second
switch 66 such that one contact 68 of each contact pair in switches
64, 66 may ride against cam surfaces 180, 182, respectively.
Rotation of stem 188 causes simultaneous rotation of rotor 100 and
movement of first and second cam surfaces 180, 182 along first and
second switches 64, 66. Accordingly, the peripheral surface shape
of cam surfaces 180, 182 operates switches 64, 66 upon rotation of
rotor 100 via rotation of valve stem 188.
On an end of rotor 100 opposite from end body 184, a flange 192 is
provided with notches 196, 198. In the assembled configuration,
pedestals 98 are received in notches 196, 198 to prevent unintended
rotation of rotor 100. Accordingly, during transport, manipulation
and installation the relative positioning of rotor 100 with respect
to switch housing part 60 and mounting part 62 can be maintained to
facilitate installation on gas valves 26. Providing a pedestal 98
in each notch 196, 198 enhances fixed, balanced positioning of
rotor 100. Other types of rotation inhibiting structures also can
be used.
A rotor of the present invention can have numerous configurations
for operating switches 64, 66. As illustrated in FIGS. 12 and 13,
rotor 200 includes central bodies 202, 204, 206 for receiving shaft
188 while providing open channels 208, 210, 212 extending axially
through rotor 200. Any fluids migrating into rotor 200 can drain
effectively therefrom without unduly hindering operation of the
switch via an open passage defined through the switch including
aperture 110, aperture 122 and channels 208, 210 and 212.
For mold design simplicity and manufacturing efficiency, flange 192
can be as wide as or wider than all portions of second cam surface
182, which is at all points thereof as wide as or wider than all
portions of first cam surface 180. By providing no blind setbacks,
mold design is simplified.
Switch housing part 60, mounting part 62 and rotor 100 can be made
from suitable plastic materials. Contacts 68 are desirably thin and
narrow, to provide an overall assembly that is small. Suitable
materials for contact 68 include beryllium-copper, phosphor-bronze
and stainless steel. Other conductive materials with suitable
mechanical properties also can be used.
In the assembly of switch assembly 20, a different contact 68 is
connected to each of conductors 38, 40, 42, 44. Two of the contacts
68 that are electrically connected to conductors 38 and 40 for a
first circuit switch 64 are positioned between side panel 82 and
the confronting wall segments 94 associated therewith,
substantially against the inner surface of base 80. Conductors 38
and 40 are disposed along the inner surface of base 80 on opposite
sides. The second pair of contacts 68 electrically connected to
conductors 42 and 44 for second circuit switch 66 is positioned
between side panel 84 and the confronting wall segments 94
associated therewith. Locating features 102 on base 80 retain
contacts 68 for second switch 66 at a greater distance from base 80
than contacts 68 for first switch 64, and second conductors 42, 44
are stacked on conductors 38 and 40, respectively.
Rotor 100 is installed between barrier segments 96, with end edge
190 thereof disposed in channel 112 and first and second cam
surfaces 180, 182 aligned with first and second switches 64, 66,
respectively. The completed assembly of switch housing part 60,
first and second switches 64, 66 disposed therein connected to
conductors 38, 40, 42 and 44, with rotor 100 positioned therein is
illustrated in FIG. 9. By replacing rotor 100 with a rotor of
different outer configuration the switching functions and
relationships between switch 64 and switch 66 can be changed.
One of the advantages of a preferred embodiment of the present
invention is that the completed assembly of switch housing part 60
with switches 64, 66 therein can be produced for use with a variety
of different rotors 100 for different switching operations and with
a variety of different mounting parts 62 for connection to
different types of gas valves in different frameworks and
structures.
With the appropriate rotor 100 inserted therein, switch assembly 20
is completed by placing mounting part 62 over switch housing part
60. Complementary engagement features that are non-symmetrical,
such as a single latch loop 104 on one side of switch housing part
60 and two latch loops 106, 108 on an opposite side of switch
housing part 60 for association with one protrusion 132 on one side
of mounting part 62 and two protrusions 134, 136 on an opposite
side of mounting part 62, facilitate proper orientation of the
parts to attach mounting part 62 only one way with respect to
switch housing part 60. Accordingly, the locating features 148, 150
on the inner surface of base 120 of mounting part 62 are properly
positioned for securing first and second switches 64, 66 in proper
position, and for covering and securing the positions of conductors
38, 40, 42 and 44.
Multiple dual function switch assemblies 20 can be installed in
similar manner at selected locations along conductors 38, 40, 42
and 44 to provide a preassembled wire harness 24 for installation
in an appliance 22, such as a gas cooking range or the like, to
provide electrical switch functions associated with multiple gas
valves 26. Thereafter, preassembled wire harness 24 can be
installed in the appliance 22 by inserting dual function switch
assemblies 20, with aligned apertures 110, 122 and opening 186,
over valve stems 188 of gas valves 26. Conductors 38, 40, 42 and 44
are connected to the additional circuit components, including, for
example, electronic ignition modules, indicator lights, audible
buzzers, etc.
For connection to different types of valves and/or different types
of frames, similar switch housing parts 60 having switches 64 and
66 can be connected to different types and arrangements for
mounting part 62. Various different rotors can be associated
therewith for operating first and second switches 64, 66 in
different sequences.
Variations and modifications of the foregoing are within the scope
of the present invention. It is understood that the invention
disclosed and defined herein extends to all alternative
combinations of two or more of the individual features mentioned or
evident from the text and/or drawings. All of these different
combinations constitute various alternative aspects of the present
invention. The embodiments described herein explain the best modes
known for practicing the invention and will enable others skilled
in the art to utilize the invention. The claims are to be construed
to include alternative embodiments to the extent permitted by the
prior art.
Various features of the invention are set forth in the following
claims.
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